A Physics-Based Predictive Model for Number of Contact Grains and Grain Depth of Cut in Honing

Honing is a material removal process widely used in manufacturing of engine cylinders, compressors, valves, bearings, and hydraulic cylinders. The surface topography generated by honing has a profound effect on the tribological performance of the honed surface, since the cross-hatch pattern on the workpiece surface can be used to retain oil or grease to ensure proper lubrication and minimize wear. The number of contact grains and the grain depth of cut are important indicators of interactions between the tool and workpiece in the honing process. They are helpful in understanding chip formation, tool wear, and optimization of the cross-hatch pattern to improve the tribological performance of the honed surface. This article presents a physics-based model for predicting the number of contact grains and the grain depth of cut in honing. It describes the model development and studies the influences of abrasive grain size, abrasive concentration, nominal contact area, yield strength of workpiece material, and static load on the number of contact grains and the maximum grain depth of cut. Results from pilot experiments are used to verify the model.